Nickel-base weld materials, processes of using, and components formed therewith

Abstract

Nickel-base alloys suitable for use as a weld material to weld high-temperature components ( 10 ), such as turbine blades and vanes of gas turbine engines. The nickel-base alloys consist essentially of, by weight, 5 to 10 percent chromium, 3 to 14 percent cobalt, up to 4 percent molybdenum, 3 to 7 percent tungsten, 5 to 9 percent tantalum, 5 to 8 percent aluminum, 0.1 to 2 percent hafnium, 0.005 to 0.03 percent boron, up to 0.15 percent carbon, the balance being nickel and incidental impurities and/or residual elements. Welds ( 12 ) formed with the alloys are capable of exhibiting desirable levels of strength and oxidation resistance, while containing little if any rhenium.

1 . A nickel-base alloy for use as weld material, the nickel-base alloy consisting essentially of, by weight:
 5 to 10 percent chromium;   3 to 14 percent cobalt;   up to 4 percent molybdenum;   3 to 7 percent tungsten;   5 to 9 percent tantalum;   5 to 8 percent aluminum;   0.1 to 2 percent hafnium;   0.005 to 0.03 percent boron;   up to 0.15 percent carbon;   the balance being nickel and incidental impurities and residual elements.   
     
     
         2 . The nickel-base alloy according to  claim 1 , wherein the nickel-base alloy contains 11 to 14 weight percent cobalt, 4.0 to 7.0 weight percent tungsten, and 5.0 to 7.0 weight percent aluminum. 
     
     
         3 . The nickel-base alloy according to  claim 1 , wherein the nickel-base alloy contains 1.5 to 2.5 weight percent molybdenum, 6.0 to 7.0 weight percent tungsten, and less than 1.3 weight percent hafnium. 
     
     
         4 . The nickel-base alloy according to  claim 1 , wherein the nickel-base alloy contains 5.1 to 5.4 weight percent tungsten and 6.4 to 7.6 weight percent aluminum. 
     
     
         5 . The nickel-base alloy according to  claim 1 , wherein the nickel-base alloy consists essentially of, by weight, about 6.8 percent chromium, about 11.6 percent cobalt, about 2.0 percent molybdenum, about 6.5 percent tungsten, about 6.35 percent tantalum, about 6.1 percent aluminum, about 1.0 percent hafnium, about 0.015 percent boron, about 0.12 percent carbon, and the balance being nickel and incidental impurities and residual elements. 
     
     
         6 . The nickel-base alloy according to  claim 1 , wherein the nickel-base alloy consists essentially of, by weight, about 7.4 percent chromium, about 3.1 percent cobalt, about 0.1 percent molybdenum, about 5.25 percent tungsten, about 5.5 percent tantalum, about 7.0 percent aluminum, about 0.13 percent hafnium, about 0.01 percent boron, about 0.007 percent carbon, and the balance being nickel and incidental impurities and residual elements. 
     
     
         7 . The nickel-base alloy according to  claim 1 , wherein the nickel-base alloy is in the form of a weld ( 12 ) on a turbine component ( 10 ) of a gas turbine engine. 
     
     
         8 . The nickel-base alloy according to  claim 7 , wherein the turbine component ( 10 ) is formed of a gamma-prime precipitation-strengthened nickel-base superalloy. 
     
     
         9 . The nickel-base alloy according to  claim 8 , wherein the turbine component ( 10 ) is a turbine blade or turbine nozzle. 
     
     
         10 . A process of using the nickel-base alloy according to  claim 1  to weld a component ( 10 ), the process comprising welding the component by melting and depositing the nickel-base alloy on the component to form a weld ( 12 ) on the component. 
     
     
         11 . The process according to  claim 10 , wherein the weld ( 12 ) repairs a flaw ( 18 ) in the component ( 10 ). 
     
     
         12 . The process according to  claim 10 , wherein the weld ( 12 ) joins at least two subcomponents ( 14 , 16 ) to form the component ( 10 ). 
     
     
         13 . A process of welding a component ( 10 ), the process comprising melting and depositing a nickel-base alloy on the component ( 10 ) to form a weld ( 12 ) on the component ( 10 ), the nickel-base alloy consisting essentially of, by weight:
 5 to 10 percent chromium;   3 to 14 percent cobalt;   up to 4 percent molybdenum;   3 to 7 percent tungsten;   5 to 9 percent tantalum;   5 to 8 percent aluminum;   0.1 to 2 percent hafnium;   0.005 to 0.03 percent boron;   up to 0.15 percent carbon;   the balance being nickel and incidental impurities and residual elements.   
     
     
         14 . The process according to  claim 13 , wherein the nickel-base alloy contains 1.5 to 2.5 weight percent molybdenum, 6.0 to 7.0 weight percent tungsten, and less than 1.3 weight percent hafnium. 
     
     
         15 . The process according to  claim 13 , wherein the nickel-base alloy contains 5.1 to 5.4 weight percent tungsten and 6.4 to 7.6 weight percent aluminum. 
     
     
         16 . The process according to  claim 13 , wherein the component is a turbine component ( 10 ) of a gas turbine engine. 
     
     
         17 . The process according to  claim 16 , wherein the turbine component ( 10 ) is formed of a gamma-prime precipitation-strengthened nickel-base superalloy. 
     
     
         18 . The process according to  claim 16 , wherein the weld ( 12 ) repairs a flaw ( 18 ) in the turbine component ( 10 ). 
     
     
         19 . The process according to  claim 16 , wherein the weld ( 12 ) joins at least two subcomponents ( 14 , 16 ) to form the turbine component ( 10 ). 
     
     
         20 . The turbine component ( 10 ) welded by the process of  claim 16 .